TWR Lighting AA1-M User manual

4300 WINDFERN RD., SUITE 100 HOUSTON, TX 77041-8943
VOICE [phone] FAX [phone]
WEB: www.twrlighting.com
IMPORTANT!!!!
PLEASE TAKE THE TIME TO FILL OUT THE FORM COMPLETELY. FILE
IN A SAFE PLACE. IN THE EVENT YOU EXPERIENCE PROBLEMS WITH
OR HAVE QUESTIONS CONCERNING YOUR CONTROLLER, THE
FOLLOWING INFORMATION IS NECESSARY TO OBTAIN PROPER
SERVICE AND PARTS.
MODEL # ________AA1-M
SERIAL #
PURCHASE DATE
PURCHASED FROM

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TABLE OF CONTENTS
1.0 GENERAL INFORMATION...............................................................................................4
2.0 INSTALLATION ................................................................................................................5
2.1 POWER SUPPLY CONTROL CABINET MOUNTING..........................................5
2.2 EXTERNAL PHOTOCELL WIRING ......................................................................6
2.3 POWER WIRING...................................................................................................6
2.4 RED BEACON, SIDELIGHT AND LOAD BALANCE RESISTOR WIRING...........6
2.5 RED BEACON AND SIDELIGHT ALARM WIRING...............................................7
3.0 THEORY OF OPERATION...............................................................................................9
3.1 THE POWER SUPPLY..........................................................................................9
3.2 THE SIDELIGHTS.................................................................................................9
3.3 BEACON ...............................................................................................................9
3.4 LOAD BALANCE RESISTOR................................................................................9
4.0 MAINTENANCE GUIDE..................................................................................................10
4.1 RED OBSTRUCTION LIGHTING........................................................................10
4.2 L-864 LAMP REPLACEMENT.............................................................................10
4.3 LAMP REPLACEMENT.......................................................................................10
4.4 L-864 CONTROLLER..........................................................................................11
4.4 PHOTOCELL.......................................................................................................11
5.0 MAJOR COMPONENTS LIST ........................................................................................12
6.0 SUGGESTED SPARE PARTS LIST...............................................................................13
WARRANTY & RETURN POLICY
RETURN MERCHANDISE AUTHORIZATION FORM (RMA)

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APPENDIX
CHASSIS LAYOUT................................................................................................1113-R
SCHEMATIC LAYOUT...........................................................................................1113-S
TROUBLE SHOOTING FLOW CHART..................................................................1113-F
PHOTOCELL HOUSING DETAIL ......................................................................... 100239
TOWER LIGHTING KIT 151’ TO 200’....................................................................260-11
...............................................................................................................................260-13
TOWER LIGHTING KIT 201’ TO 350’....................................................................260-12
...............................................................................................................................260-14
OL-1 LIGHT LEVEL DETAIL................................................................................. 100188
L-810 OL-1 SINGLE OBSTRUCTION LIGHT ....................................................FM10018
L-810 OL-1 SINGLE OBSTRUCTION LIGHT DETAIL.......................................... 279-OL
L-810 OL-1 WIRING DETAIL...................................................................................274-S
L-864 FM 300 MM BEACON..............................................................................FM10017
L-864 FM 300 MM BEACON....................................................................................275-B
L-864 FM 300 MM WIRING DETAIL........................................................................273-B
LOAD BALANCE RESISTOR DETAIL.....................................................................276-R
JUNCTION BOX DETAIL...................................................................................... 100089

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1.0 GENERAL INFORMATION
The TWR Model AA1-M Controller is for A1 lighting of towers 151’ to 350’ above ground
level (AGL) in accordance with the Federal Advisory Circular 70/7460-1K. One (1) beacon
should be placed at the top of the structure. Three(3)obstruction lights should be placedat
the mid-point with respect to overall tower height.
The flash rate of the beacons is 30 per minute. The sidelights burn steady.
A by-pass switch (SW1) allows the controller to be turned on during daylight hours without
covering the photocell. This is particularly helpful since the controller can be mounted
indoors while the photocell is outdoors. SW1 can be operated by turning “on” the toggle
switch mounted on the panel of the controller.
The beacon requires two (2) 620 watt or two (2) 700 watt, 120V bulbs. The use ofany other
bulb may give a false beacon lamp burnout alarm. TWR recommends that you use only
these bulbs. Do not try to use 130V bulbs. Each sidelight requires (1) 116 watt, 120V bulb
(620PS40P, 700PS40P and 116A21TS).
The photocell is the tree (3) blade, twist to lock, type.
Power supplied to the controller shall be 120V, 50/60 Hz.
The controller housing is rated at NEMA 4X. It is suitable for indoor or outdoor mounting.
Controller functions that are monitored by remote alarms in the form of dry contact closures
(Form C) are as follows:
POWER FAILURE Monitors 120V AC to the controller. Alarms in the event of
power failure or tripped circuit breaker.
LIGHTS “ON” Gives an indication whenever the controller is activated.
BEACON Will give an alarm in the event of one (1) or both bulbs failing
or flasher stalling.
FLASHER FAILURE Will give an alarm in the event of flasher failure.
OBSTRUCTION LIGHTS Will give an alarm when one (1) of three (3) sidelights fail.

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2.0 INSTALLATION
WARNING DANGER!!!
THIS SYSTEM OPERATES AT HIGH VOLTAGE LEVELS THAT COULD BE LETHAL TO
SERVICE PERSONNEL. ALL INSTALLATION AND MAINTENANCE WORK SHOULD
BE DONE BY QUALIFIED SERVICE PERSONNEL ONLY. WHEN PERSONNEL IS
INSTALLING SYSTEM OR PERFORMING MAINTENANCE ON THIS SYSTEM, MAKE
SURE THE POWER IS TURNED OFF AT THE SERVICE BREAKER PANEL!!
READ AND UNDERSTAND THE THEORY OF OPERATION AND ITS SAFETY
MESSAGES BEFORE ATTEMPTING INSTALLATION/MAINTENANCE OF THIS
SYSTEM. DO NOT ATTEMPT TO DEFEAT THE INTERNAL SAFETY SWITCHES IN THE
CONTROLLER AND BEACON!!
2.1 POWER SUPPLY CONTROL CABINET MOUNTING
2.1.1 The power supply control cabinet can be located at the base of thestructure
or in an equipment building. Mounting footprints are shownon Drawing 113-
R. Power wiring to the control cabinet should be in accordance with local
methods and National Electrical Codes (NEC).
2.1.2 If the control cabinet is mounted inside an equipment building, the photocell
should be mounted vertically on ½” conduit outside the building above the
eaves facing north. Wiring from the photocell socket to the control cabinet
should consist of one (1) each, red, black and white wires. The white wire is
connectedtothe socket terminal marked “COM”,theblack wire is connected
to the socket terminal marked “B”, and the red wire is connected to the
socket terminal marked “R”. These socket connections are made by using
.25’ quick connect terminals, which must becrimped to the wires. As above,
the photocell should be positioned so that it does not “see” ambient light,
which would prevent it from switching to the nightmode.
2.1.3 If thecontrol cabinet is mounted outside anequipment building,thephotocell
should be mounted vertically on ½” conduit so the photocell is above the
control cabinet. Care must be taken to assure that the photocell does not
“see” any ambient light that would prevent it from switching into the
nightmode. The photocell wiring is the same as in 2.1.1.
2.1.4 The wiring from the photocell, the service breaker, the red incandescent
beacon, and the sidelights should enter the control cabinet through the
watertight connectors in the bottom of the cabinet. Inside the cabinet, the

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connections will be made on the terminal strips and circuit breakers located
at the bottom of the chassis. These connections are made as follows:
2.2 EXTERNAL PHOTOCELL WIRING (Refer to Drawing 1113-R)
2.2.1 Connect the BLACK wire from the photocell to terminal block TB2 marked
“L”.
2.2.2 Connect the RED wire from the photocell to terminal block TB2 marked
“SSR”.
2.2.3 Connect the WHITE wire from the photocell to terminal block TB2 marked
“N”.
2.3 POWER WIRING (Refer to Drawing 1113-R)
2.3.1 Power wiring to the control cabinet should be in accordance with local
methods and National Electrical Codes (NEC).
2.3.2 Circuit breaker needs to be rated at 20 amps.
2.3.3 Connect incoming 120V AC line to terminal block TB1 marked “L”.
2.3.4 Connect the neutral wire(s) to one (1) of the terminal blocks on TB1 marked
“N”.
2.3.5 Connect the AC ground to the aluminum mounting plate.
2.4 RED BEACON, SIDELIGHT and LOAD BALANCE RESISTOR WIRING (Refer to
Drawings 1113-R, 260-11 through 260-14 and 276-R)
Install wiring between the controller to the beacon utilizing either strobe cable or
conduit method. Refer to Drawings 1113-R, 260-11 through 260-14 and 276-R, for
installation of light kits. Following these requirements,installinglightkits will require
lifting of the cable by the supplied cable grip or conduit to affix to the tower. Always
work safely and adhere to all OSHA Safety Guidelineswhen lifting wiring or working
on the structure or tower itself. It is the installer’s responsibility toinstall the lighting
kit in a safe manner. Installers can request from OSHA their requirements 29CFT
1926.21, and 20CFR 1926.105 to ensure compliance to regulations.
NOTE: On occasion, a set of custom lighting kit drawing may be specifically
requested by a customer and installed in this manual. Incases such as these,
the drawings will proceed the manual if a conflict occurs.
2.4.1 Connect the BLACK wire from the beacon to the circuit breakermarked “B”.

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2.4.2 Connect the RED wire from the sidelight group to the circuit breaker marked
“S”.
2.4.3 Connect the BLACK wire from the Load Balance Resistor (optional) to the
circuit breaker marked “R”.
2.4.4 Connect the NEUTRAL wire(s) to one of the terminal blocks on TB1 marked “N”.
WARNING DANGER!!!
THIS SYSTEM OPERATES AT HIGH VOLTAGE LEVELS THAT COULD BE
LETHAL TO SERVICE PERSONNEL. ALL INSTALLATION AND MAINTENANCE
WORK SHOULD BE DONE BY QUALIFIED SERVICE PERSONNEL ONLY.
WHEN PERSONNEL IS INSTALLING SYSTEM OR PERFORMING
MAINTENANCE ON THIS SYSTEM, MAKE SURE THE POWER IS TURNED OFF
AT THE SERVICE BREAKER PANEL!!
READ AND UNDERSTAND THE THEORY OF OPERATION AND ITS SAFETY
MESSAGES BEFORE ATTEMPTING INSTALLATION/MAINTENANCE OF THIS
SYSTEM. DO NOT ATTEMPT TO DEFEAT THE INTERNAL SAFETY SWITCHES
IN THE CONTROLLER AND BEACON!!
2.5 RED BEACON AND SIDELIGHT ALARM WIRING (Refer to Drawing 1113-R)
2.5.1 Alarm relays K1-K3, and alarm Modules M1 and M4,are provided
for independent contact closures for: Power Failure, Lights “ON”,
Beacon Flasher Failure, Beacon Lamp Burnout and Sidelight
Lamp Burnout.
2.5.2 Alarm wiring: To utilize all of the red light alarms, the customer
will need five (5) pair of wires to interface with his alarm device.
One (1) wire from each of the five (5) pair will terminate at the
points marking common (C). The remaining wire from each
pair will terminate as follows:
2.5.2.1 Power Failure Alarm: Connect to relay K1,
terminal #3, for normally open (OR) terminal #6, for normally
closed monitoring.
2.5.2.2 Lights “ON” Alarm: Connect to relay K2, terminal
#3, for normally open (OR) terminal #6, for
normally closed monitoring.
2.5.2.3 Beacon Flasher Failure: Connect to relay K3,

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terminal #6, for normallyopen(OR) terminal #3, for
normally closed monitoring.
2.5.2.4 Beacon Lamp Burnout: Connect to Module M1,
terminal T6, for normally open (OR) terminal T7,
for normally closed monitoring.
2.5.2.5 Sidelight Lamp Burnout: Connect to Module M4,
terminal T5, for normally open (OR) terminal T6,
for normally closed monitoring.
2.5.3 Alarm testing: To test alarms, follow the procedures using an “ohm” meter between
alarm common and alarm pints.
2.5.3.1 Power Failure: Pull circuit breaker at electrical panel.
2.5.3.2 Lights “ON”: Operate photocell by-pass switch (SW1) or cover the
photocell. NOTE: (Indication will be delayed 8 – 10 seconds for all the
beacon and sidelight relays to position themselves.)
2.5.3.3 Beacon and Sidelights: Trip circuit breakers on the controller panel.

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3.0 THEORY OF OPERATION
3.1 THE POWER SUPPLY
120V AC enters the controller from the circuit breaker panel. Lines sit at the PRD,
waiting to be switched, and also keeps the power failure relay K1 energized. When
the 102FAA photocell is activated, line energizes the coil of the PRD and K2 “Lights
On” relay. This also can be accomplished by using the photocell by-pass switch
(SW1).
3.2 SIDELIGHTS
Line LD is sent through ModuleM4, which is acurrent sensing module for sidelights.
Each SCR430T monitors one (1) level of sidelights, and will provide a contact
closure along a visual indication of one (1) or more lamps fail.
3.3 BEACON
Line LDB is sent to Modules M1, M2 and M3. Module M2 is the primary flasher for
the beacon, which provides control voltage to Module M3, which is an auxiliary
flasher for the load balance resistor. The output of Module M2 is sent through the
current sensing Module M1 to the circuit breaker output “B”. If Module M1 detectsa
lamp burnout, then that module would provide a contact closure along with avisual
indication for the lamp circuit.
Relay K3 is a flasher failure relay for the beacon. If Module M1 detects a flasher
failure, then that module would provide voltage to relay K3, which would provide a
contact closure alone with a visual indication for that beacon circuit.
3.4 LOAD BALANCE RESISTOR
The output of Module M2 (pin #1) is sent to Module M3 for timing purposes. Module
M3 output (pin #1) will operate alternately to the primary flasher’s output. The load
balance resistor (optional) will only be on between flasher to the beacon toeventhe

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current draw on the generator system.

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4.0 MAINTENANCE GUIDE
**WARNING - HIGH - VOLTAGE**
THIS SYSTEM OPERATES AT HIGH VOLTAGE LEVELS THAT COULD BE
LETHAL TO SERVICE PERSONNEL. ALL INSTALLATION AND MAINTENANCE
WORK SHOULD BE DONE BY QUALIFIED SERVICE PERSONNEL. READ AND
UNDERSTAND THE THEORY OF OPERATION AND ITS SAFETY MESSAGES
BEFORE ATTEMPTING INSTALLATION OF THIS SYSTEM. DO NOT ATTEMPT
TO DEFEAT THE INTERNAL SAFETY DEVICES.
Tools Required: NONE
4.1 RED OBSTRUCTION LIGHTING
The only required maintenance needed to be performed is the replacement of the
lamps in the L-864 and L-810 fixtures. Lamps should be replaced after being
operated for not more than 75% of the rated life or immediately upon failure as per
the Federal Advisory Circular 70/7460-1K. By following these instructions,
maximum safety and performance can be achieved.
4.2 L-864 LAMP REPLACEMENT
4.1.1 Loosen the one (1) wing nut on the latch pin so that it can recline.
4.1.2 Open the lens and tilt it back.
4.1.3 To remove each lamp, depress down while rotating the lamp counter-
clockwise 90 degrees,
4.1.4 Install the new lamps by depressing down while rotating the lamp clockwise
90 degrees.
4.1.5 Close the lens and let the latch pin drop in the recessed slot.
4.1.6 Tighten the wing nut snug, then ¼ turn more.
4.2 LAMP REPLACEMENT
4.2.1 Unclasp the two (2) latches and let the bail recline back.
4.2.2 Lift the lens up and over the lamp letting the lens hang fromthe safety cable.
4.2.3 Unscrew the lamp counter-clockwise and remove.

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4.2.4 Install the new lamp by screwing the lamp clockwise.
4.2.5 Reinstall the lens; making sure it is seated properly on the base.
4.2.6 Reclasp the two (2) latches.
4.3 L-864 CONTROLLER
No scheduled maintenance is required. Perform on an “as needed” basis
only.
4.4 PHOTOCELL
The photocell is a sealed unit. No maintenance is needed or required other than
replacement as necessary.

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5.0 MAJOR COMPONENTS LIST
QUANTITY # DESCRIPTION PART NUMBER
1 PHOTOCELL 102FAA
1 SOLID STATE FLASHER (M2) FS15530T
1 SOLID STATE AUXILIARY FLASHER (M3) FA155
1 MECHANICAL LOAD CONTACTOR (PRD) PRD7AGO
1 BEACON FAILURE DETECTOR (M1) FN120A
2 SPDT RELAY (K1 AND K3) X9KE-115V
1 SIDELIGHT BURNOUT DETECTOR (M4) SCR430T
1 TIME DELAY RELAY (K2) SPEC224
1 ENCLOSURE VJ1412HWPL2
1 15 amp SPDT SWITCH (SW1) STJ02002
4 METAL OXIDE VARISTOR (MOV1 – MOV4) MOV524V15
3 20 amp BREAKER (B, R, AND S) 5SX2120-8
2 END STOP 8WA1808
6 TERMINAL BLOCKS (TB1, TB2) 8WA1204
3 OCTAL SOCKETS (K1-K3) PB27E122

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6.0 SUGGESTED PARTS LIST
QUANTITY# PART NUMBER DESCRIPTION
1 102FAA PHOTOCELL
1 FS15530T SOLID STATE FLASHER (M2)
1 PRD7AGO LOAD CONTACTOR (PRD)

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Warranty & Return Policy
TWR Lighting, Inc. (“TWR”) warrants its products (other than replacement parts) against
defects in design, material (excluding incandescent bulbs) and workmanship for a period ending
on the earlier of two (2) years from the date of shipment or one (1) year from the date of
installation.
Replacement parts are warranted for 90-days from the date of shipment.
Conditions not covered by this Warranty or which might void this Warranty are as follows:
•Improper Installation or Operation
•Misuse
•Abuse
•Unauthorized or Improper Repair or Alteration
•Accident or Negligence in Use, Storage, Transportation, or Handling
•Any Acts of God or Nature
Field Service – Repairs are warranted for 90 days from the date of service, except where TWR has
made recommendations that were not adhered to that may cause premature failure on previous repairs.
Labor, Travel, and Tower Climb are not covered under warranty. Customer shall be obligated to pay for
all incurred charges not related to warranty. All warranty repairs are performed by trained TWR
personnel, or dispatched through an extensive network of certified and insured subcontractors.
Return Policy
Return Terms – You must first contact our Product Support Administrative Assistant at (713-973-
6905) to acquire a Return Goods Authorization (RGA) number in order to return the product(s). Please
have the following information available when requesting an RGA number:
•The contact name and phone number of the tower owner
•The contact name and phone number of the contractor
•The site name and number
•The part number
•The serial number (if any)
•A description of the problem
•The billing information
•The Ship To address
This RGA number must be clearly visible on the outside of the box. If the RGA number is not
clearly labeled on the outside of the box, your shipment will be refused. Please ensure the material you
are returning is packaged carefully. The warranty is null and void if the product(s) are damaged in
the return shipment.
All RGA’s must be received by TWR 4300 Windfern Rd., Suite 100, Houston TX 77041-8943,
within 30 days of issuance.
Upon full compliance with the Return Terms, TWR will replace, repair and return, or credit products
returned by the customer. It is TWR’s sole discretion to determine the disposition of the returned
item(s).

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Replacements – Replacement part(s) will be shipped and billed to the customer for product(s)
considered as Warranty, pending return of defective product(s). When available, a certified
reconditioned part is shipped as warranty replacement with a Return Goods Authorization (RGA)
number attached. Upon receipt of returned product(s), inspection, testing and evaluation will be
performed to determine the cause of defect. The customer is then notified of the determination of the
testing.
•Product(s) that is deemed defective and/or un-repairable and covered under warranty, a credit
will be issued to the customer’s account.
•Product(s) that are found to have no defect will be subject to a $60.00 per hour testing charge
(1 hour minimum), which will be invoiced to the customer. At this time the customer may
decide to have the tested part(s) returned and is responsible for the return charges.
•Product(s) under warranty, which the customer does not wish returned, the customer will be
issued a credit against the replacement invoice.
Repair & Return – A Return Goods Authorization (RGA) will be issued for all part(s) returned to
TWR for repair. Upon receipt of returned product(s), inspection, testing and evaluation will be
performed to determine the cause of defect. The customer is then notified of the determination of the
testing. If the returned part(s) is deemed un-repairable or the returned part(s) is found to have no
defect, the customer will be subject to a $60.00 per hour testing charge (1 hour minimum), which
will be invoiced to the customer. Should the returned parts be determined to be repairable, a written
estimated cost of repair will be sent to the customer for their written approval prior to any work being
performed. In order to have the tested part(s) repaired and/or returned, the customer must issue a
purchase order and is responsible for the return shipping charges.
Return to Stock – Any order that is returned to TWR for part(s) ordered incorrectly by the customer or
unneeded upon receipt, the customer is required to pay a 20% restocking fee. A credit will be issued
once it is determined that the Return Terms are met.
Credits – Credits are issued once it is determined that all of the Warranty and Return Terms are met.
All credits are processed on Fridays. In the event a Friday falls on a Holiday, the credit will be issued on
the following Friday.
Freight – All warranty replacement part(s) will be shipped via ground delivery and paid for by TWR.
Delivery other than ground is the responsibility of the customer.
REMEDIES UNDER THIS WARRANTY ARE LIMITED TO PROVISIONS OF REPLACEMENT PARTS AND
REPAIRS AS SPECIFICALLY PROVIDED. IN NO EVENT SHALL TWRBELIABLE FOR ANY OTHER LOSSES,
DAMAGES, COSTS OR EXPENSES INCURED BY THE CUSTOMER, INCLUDING BUT NOT LIMITED TO,
LOSS FROM FAILURE OF THE PRODUCTS TO OPERATE FOR ANY TIME, AND ALL OTHER DIRECT,
INDIRECT, SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMANGES, INCLUDIG ALL PERSONAL
INJURY PROPERTY DAMAGE DUE TO ALLEGED NEGLIGENCE, STRICTLY LIABLE, OR ANY OTHER
LEGAL THEORY WHATSOEVER. THIS WARRANTY IS MADE BY TWR EXPRESSLY IN LIEU OF ALL
OTHERWARRANTIES, WHETHER EXPRESS OR IMPLIED. WITHOUT LIMITING THE GENERALITY OF THE
FOREGOING,TWR MAKESNO WARRANTY OF MERCHANTABILITY OR FITNESSOF THEPRODUCTSFOR
ANY PARTICULAR PURPOSE. TWR EXPRESSLY DISCLAIMS ALL OTHER WARRANTIES.

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RETURN GOODS AUTHORIZATION FORM (RGA)
RGA#: DATE:
CUSTOMER:
CONTACT: PHONE NO.:
ITEM DESCRIPTION (PART NO.):
MODEL NO.: SERIAL NO.:
ORIGINAL TWR INVOICE NO.: DATED:
DESCRIPTION OF PROBLEM:
SIGNED DATE NEEDED
RETURN ADDRESS:
PLEASE RETURN PRODUCT TO: 4300 WINDFERN RD #100 HOUSTON TX 77041-8943

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RETURN GOODS AUTHORIZATION FORM (RGA)
RGA#: DATE:
CUSTOMER:
CONTACT: PHONE NO.:
ITEM DESCRIPTION (PART NO.):
MODEL NO.: SERIAL NO.:
ORIGINAL TWR INVOICE NO.: DATED:
DESCRIPTION OF PROBLEM:
SIGNED DATE NEEDED
RETURN ADDRESS:
PLEASE RETURN PRODUCT TO: 4300 WINDFERN RD #100 HOUSTON TX 77041-8943